Edge closure for roof systems

ABSTRACT

An edge closure for installation on a roof structure is fabricated as an integral unit from a non-corrosive, durable material. The edge closure includes an anchoring flange for attachment to the roof structure, an upper flange with an upper longitudinal edge zone, and intermediate panel spanning between the anchoring flange and the upper flange, and a fascia portion integral with the anchoring flange and extending downwardly to a lower longitudinal edge zone. The anchoring flange and upper flange are spaced apart for receiving a thickness of insulative lightweight concrete therebetween. The upper and lower longitudinal edge zones are angled to provide added rigidity and strength to the edge closure.

This non-provisional patent application is based on provisional patent application Ser. No. 60/802,240 filed on May 17, 2006.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to blocking for use in roof systems and, more particularly, to an edge closure formed as one piece from a non-corrosive, durable material, such as steel, galvanized steel, aluminum or plastic.

2. Discussion of the Related Art

Generally, roof systems used on most building structures, and particularly commercial buildings, require some type of blocking to provide a base for the attachment of roofing components such as, but not limited to, gravel stops, eaves, drips, fascia, gutters, vent stacks, roof top equipment, expansion joints, roof curbs, copings and cant strips. Traditionally, wood is used for roof blocking and typically consists of one or more stacked wood boards (e.g. 2 inch by 4 inch or 2 inch by 6 inch boards) that are nailed to the roof structure and each other in order to provide a built-up base at various locations on the roof system where it is necessary to mount the roofing components and equipment. Presently, wood blocking is the most common type of blocking used in roof systems which require blocking for the purposes described above.

Despite its widespread use in roof systems, there are significant drawbacks and shortcomings associated with the use of conventional wood blocking. In particular, wood is susceptible to damage and deterioration from moisture, termites, ants, and other natural enemies. Further, because wood is a solid material, it does not provide for venting capabilities to permit escape of moisture and gasses from within the roof. The lack of adequate venting is a contributing factor of premature roof failure. Additionally, wood has limited pull-out characteristics for holding nails and other fasteners, thereby requiring a considerable amount of hardware to attach roofing components. Wood, being a natural product, is also prone to irregularities such as areas of reduced dimension, warping, and splintering. This makes it difficult, if not impossible, to achieve a straight, uniform blocking configuration. Furthermore, the dimensions of wood are limited to lumber industry standards which often does not correspond to the dimensions of roofing components, such as roof insulation or lightweight concrete thickness, expansion joint heights and equipment sizes.

In view of the shortcomings of tradition wood blocking used in roof systems, as set forth above, there remains a definite and ongoing need in the construction industry for various alternative blocking structures that overcome the above-described problems.

OBJECTS OF THE INVENTION

With the foregoing in mind, the present invention has the following objects and advantages over the conventional wood blocking structure presently used in most roof systems.

In particular, a primary object of the present invention is to provide a blocking assembly for roof systems comprising a preformed integral unit manufactured from galvanized steel, steel, aluminum, plastic or other corrosion-resistant materials to thereby provide resistance to deterioration from moisture, insects, warping, and the like.

It is a further object of the present invention to provide a non-corrosive blocking component that is formed and/or molded in accordance with desired size and configuration specifications for use as an edge closure about the sides of a roof structure.

It is still a further object of the present invention to provide a non-corrosive blocking component having a pullout resistance that is significantly greater than that of wood, thereby requiring less hardware, labor and materials for installation.

It is yet a further object of the present invention to provide a non-corrosive blocking component that encloses the edges of a roof structure and which is formed to provide added rigidity and strength.

It is still a further object of the present invention to provide a non-corrosive edge closure for a roof structure with an integral fascia portion that extends down the side of the roof structure, and wherein the fascia portion includes an outwardly angled lower longitudinal edge zone for providing added strength and rigidity to the edge closure.

It is still a further object of the present invention to provide a non-corrosive edge closure for a roof structure that includes an angled upper longitudinal edge zone and a lower longitudinal edge zone to provide added strength and rigidity to the edge closure.

SUMMARY OF THE INVENTION

The present invention is directed to an edge closure for installation on a roof structure and replaces traditional wood blocking. The edge closure includes an anchoring flange for attachment to the roof structure, an upper flange with an upper longitudinal edge zone, and intermediate panel spanning between the anchoring flange and the upper flange, and a fascia portion integral with the anchoring flange and extending downwardly to a lower longitudinal edge zone. The anchoring flange and upper flange are spaced apart for receiving a thickness of insulative lightweight concrete therebetween. The upper and lower longitudinal edge zones are angled to provide added rigidity and strength to the edge closure.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a side perspective view of the edge closure of the present invention; and

FIG. 2 is an end elevation view of the edge closure.

Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the several views of the drawings, the perimeter or edge closure is shown and is generally indicated as 10.

The edge closure 10 is preferably fabricated from a single sheet of material by roll forming, bending or extrusion. The edge closure 10 is formed of a non-corrosive, durable material, such as, but not limited to, steel, galvanized steel, aluminum or plastic.

The edge closure 10 is formed to include an anchoring flange 12, an upper flange 14 and an intermediate panel 16 spanning between the anchoring flange 12 and the upper flange 14. The edge closure 10 also includes a fascia portion 18 extending down from the anchoring flange, and in coplanar relation to the intermediate panel.

The anchoring flange extends outwardly from the intermediate panel a greater distance than the upper flange to provide an increased surface area for mounting to the roof structure with the use of approved fasteners 19, such as #14 roof fasteners with ¾ inch washers or 1½ inch TAPCONS screws with ¾ inch washers. The greater extension of the anchoring flange 12 also provides for ease of access to the fasteners, when securing the anchoring flange to the roof structure, without interference by the upper flange 14, as seen in FIG. 2. The upper flange 14 is spaced from the anchoring flange 12 a distance generally equal to the height of the intermediate panel 16 creating an area of depth 24 between the upper flange and anchoring flange. A mouth 26 is defined between the terminal edge 20 of the upper flange 14 and the anchoring flange 12 for receipt of a thickness (i.e. layer) of insulative lightweight concrete material that fills the area of depth 24 between the upper flange 14 and anchoring flange 12.

The upper flange 14 includes an upper longitudinal edge zone 22 adjacent the terminal edge 20 and extending along the entire length of the upper flange. The upper longitudinal edge zone 22 is angled downwardly, as seen in FIG. 2. Similarly, the fascia portion 18 includes a lower longitudinal edge zone 32 extending to a lower terminal edge 30. The lower longitudinal edge zone 32 is angled outwardly, as seen in FIGS. 1 and 2. The angled upper and lower longitudinal edge zones 22, 32 provide for added rigidity and strength to the overall structure of the edge closure 10. Moreover, the downward angle of the upper longitudinal edge zone 22 allows the upper flange to bite into the applied layer of insulative lightweight concrete. The outward kick of the lower longitudinal edge zone 32 provides a convenient means for attachment of a drip edge 50, as seen in FIG. 1.

To enhance the attachment and structural integrity of the edge closure to the roof system, approved fasteners 19, such as those described above, can be used along the fascia portion 18, as seen in FIG. 1, thereby securing the fascia portion 18 to the roof structure.

In a further embodiment of the invention, the intermediate panel 16 may be provided with vent holes 40 along its length for venting moisture and gases from within the roof system.

After application of the insulative lightweight concrete, a roof membrane system or other roof covering material is applied to the lightweight concrete and a flashing strip is attached over the membrane and the upper flange 14 of the edge closure 10. A steel drip edge 50, such as that shown in FIG. 1, may be attached between the flashing and upper flange 14 of the edge closure.

While the present invention has been shown and described in accordance with a preferred and practical embodiment thereof, it is recognized that departures from the instant disclosure are fully contemplated within the spirit and scope of the invention. 

1. An edge closure for installation on a roof structure, wherein the roof structure includes a thickness of insulation, said edge closure comprising: an anchoring flange structured and disposed for attachment to the roof structure; an upper flange spaced above said anchoring flange to define an area of depth therebetween for receipt of the thickness of the insulation between said upper flange and said anchoring flange, and said upper flange including a longitudinal edge zone positioned at an angle relative to a remainder of said upper flange; an intermediate panel spanning between said anchoring flange and said upper flange; and a fascia panel integral with said anchoring flange and extending downwardly therefrom and terminating at a lower longitudinal edge zone, and said lower longitudinal edge zone being angled outwardly relative to a remainder of said fascia panel.
 2. The edge closure as recited in claim 1 wherein said longitudinal edge zone of said upper flange is angled downwardly relative to the remainder of said upper flange.
 3. The edge closure as recited in claim 2 wherein said longitudinal edge zone of said upper flange is angled downwardly for biting into the thickness of insulation.
 4. The edge closure as recited in claim 1 wherein said longitudinal edge zone of said upper flange and said lower longitudinal edge zone of said fascia panel are angled for providing added rigidity and strength to said edge closure.
 5. The edge closure as recited in claim 1 wherein said intermediate panel includes a plurality of vent holes for venting moisture and gases from within the roof structure.
 6. The edge closure as recited in claim 1 wherein said anchoring flange, said upper flange, said intermediate panel, and said fascia panel are formed as an integral unit from a single sheet of material.
 7. The edge closure as recited in claim 6 wherein said single sheet of material is galvanized steel.
 8. The edge closure as recited in claim 6 wherein said single sheet of material is steel.
 9. The edge closure as recited in claim 6 wherein said single sheet of material is aluminum.
 10. The edge closure as recited in claim 1 wherein said anchoring flange, said upper flange, said intermediate panel, and said fascia panel are formed as an integral unit.
 11. The edge closure as recited in claim 10 wherein said integral unit is formed of plastic.
 12. The edge closure as recited in claim 1 wherein said upper flange extends from said intermediate panel and terminates at said longitudinal edge zone, and said anchoring flange extends from said intermediate panel and in spaced, parallel relation to said upper flange, and said anchoring flange extends a greater distance than said upper flange from said intermediate panel.
 13. An edge closure for installation on a roof structure, wherein the roof structure includes a thickness of insulation, said edge closure comprising: an anchoring flange structured and disposed for attachment to the roof structure; an upper flange spaced above said anchoring flange to define an area of depth therebetween for receipt of the thickness of the insulation between said upper flange and said anchoring flange, and said upper flange including a longitudinal edge zone positioned at an angle relative to a remainder of said upper flange; an intermediate panel spanning between said anchoring flange and said upper flange; said anchoring flange extending from said intermediate panel and terminating at a distal longitudinal edge to define a width of said anchoring flange measured from said intermediate panel to said distal longitudinal edge; said upper flange extending from said intermediate panel to a distal longitudinal edge of said longitudinal edge zone to define a width of said upper flange measured from said intermediate panel to a said distal longitudinal edge of said longitudinal edge zone; said width of said anchoring flange being greater than said width of said upper flange; and a fascia panel integral with said anchoring flange and extending downwardly therefrom and terminating at a lower longitudinal edge zone, and said lower longitudinal edge zone being angled outwardly relative to a remainder of said fascia panel.
 14. The edge closure as recited in claim 13 wherein said longitudinal edge zone of said upper flange is angled downwardly relative to the remainder of said upper flange.
 15. The edge closure as recited in claim 14 wherein said longitudinal edge zone of said upper flange is angled downwardly for biting into the thickness of insulation.
 16. The edge closure as recited in claim 13 wherein said longitudinal edge zone of said upper flange and said lower longitudinal edge zone of said fascia panel are angled for providing added rigidity and strength to said edge closure.
 17. An edge closure for installation on a roof structure, wherein the roof structure includes a thickness of insulation, said edge closure comprising: an anchoring flange structured and disposed for attachment to the roof structure; an upper flange spaced above said anchoring flange to define an area of depth therebetween for receipt of the thickness of the insulation between said upper flange and said anchoring flange, and said upper flange including a longitudinal edge zone positioned at an angle relative to a remainder of said upper flange; an intermediate panel spanning between said anchoring flange and said upper flange; said anchoring flange extending from said intermediate panel and said upper flange extending from said intermediate panel in spaced relation above said anchoring flange, and said anchoring flange extending a greater distance from said intermediate panel than said upper flange; and a fascia panel integral with said anchoring flange and extending downwardly therefrom and coplanar with said intermediate panel, and said fascia panel terminating at a lower longitudinal edge zone, and said lower longitudinal edge zone being angled outwardly relative to a remainder of said fascia panel.
 18. The edge closure as recited in claim 17 wherein said longitudinal edge zone of said upper flange is angled downwardly relative to the remainder of said upper flange.
 19. The edge closure as recited in claim 18 wherein said longitudinal edge zone of said upper flange is angled downwardly for biting into the thickness of insulation.
 20. The edge closure as recited in claim 17 wherein said longitudinal edge zone of said upper flange and said lower longitudinal edge zone of said fascia panel are angled for providing added rigidity and strength to said edge closure. 